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Topic: Generator Won't Start (Read 2039 times) previous topic - next topic

Re: Generator Won't Start

Reply #25 –
Anyone have a line on where i can find a exploded parts schematic for my fuel injector pump assembly? I have looked but cannot seem to find anything.
Thanks
Zack & Ginny Methvin
1998 U270 36' WTFE
Build# 5242 (E-25 code)
FMCA# 548390
Longview, Texas

Re: Generator Won't Start

Reply #28 –
Long shot - have you jumpered the connections on the oil pressure sensor as a test?
Dan - Full timing since 2009
2003 U320 40' Tag 2 slide

Re: Generator Won't Start

Reply #29 –
Quote from: Zack & Ginny –
Yes, Mike pulled it to inspect the inside. Everything looked clean.
Does the injector pump cam rotate when the engine cranks?

I sent you a PM
Tim Dianics
Pam Sapienza
Vader PupZilla Labrador Canine Beast (AKA Pup)
Columbia, MO
1996 U320 4000
2021 Jeep Gladiator, Diesel

Re: Generator Won't Start

Reply #30 –
Thanks everyone for your input and suggestions.

Today I pulled all 3 injector pumps. The first one I tore down was closest to the front of the engine and it was locked up solid. When I pulled it, I noticed it was in the closed position. After taking it apart, I found the slide bar inside the pump was locked tight inside it's collar. After some soaking with penetrant, rotating the shaft, it finally turned loose. So, I am now 99.9% sure this was my problem all along. Even though the #2 & #3 pumps look good, I am going to pull them down and clean them as well. Once I get these back in, I will update everyone with the outcome.
Thanks




 
Zack & Ginny Methvin
1998 U270 36' WTFE
Build# 5242 (E-25 code)
FMCA# 548390
Longview, Texas

Re: Generator Won't Start

Reply #31 –
I'm always in awe at the skills our members here have.
1993 U300 40ft GV SE
Build # 4344

Re: Generator Won't Start

Reply #32 –
Zack,

Now you see how if one injector pump has a problem like this it will stop the fuel shut off rail from working properly. When this happens it effects the function of all the others. I bet you will be up and running before we get back to home base.

Mike
Pamela & Mike 97 U 320

"It's not what happens to you, but how you react to it that matters."

Re: Generator Won't Start

Reply #33 –
Well, still fighting the gremlins.

Today I re-installed all 3 pumps but in doing so, I had to slide the fuel rail / rack slightly back and forth to align the pump pins into the slots on the rail. On the last pump (the one I took apart), I slid the rail all the way towards the front of the engine and it snapped into position and stayed there until I manually pulled the rail back towards the rear of the engine. I continued re-adjusting the rail / rack until the pump pin finally slipped into the rail / rack slot.

After everything was hooked back up, I thought, ok, I have it now. After 3 failed start attempts the engine finally fired up but went to full throttle and blowing huge amounts of black smoke. My overspeed light came on and the master switch would not turn it off. I finally got it to shut off after unplugging the fuel shutoff solenoid. This generator has always ran perfectly so I have not bothered re-adjusting the governor or anything. Whatever reason it is going to full throttle has to be something I did wrong with manually sliding the fuel rail / rack back and forth I'm guessing. I sure wish I had a schematic to see what everything is supposed to look like inside. I have talked to Wayne & Mike about this but until I know more about how everything is supposed to set, I am fearful of running it again at max RPM's. I checked, re-checked and triple checked the re-assembly of the pump step by step. I am 100% confident that the pump I took apart is spot on correct and in time.

Anyone have any other ideas as to what I could have done that has caused this thing to rev out of control?
Zack & Ginny Methvin
1998 U270 36' WTFE
Build# 5242 (E-25 code)
FMCA# 548390
Longview, Texas

Re: Generator Won't Start

Reply #34 –
The only thing I can think of is to check the governor linkage. See if by moving the governor
linkage it is opening and closing the injectors. You may have the linkage backwards if that is
possible.
Peter and Frieda Morin
1999 36ft. U320 Foretravel
Build # 5436
1998 Suzuki Sidekick Sport

Re: Generator Won't Start

Reply #35 –
Quote from: oldguy –
The only thing I can think of is to check the governor linkage. See if by moving the governor
linkage it is opening and closing the injectors. You may have the linkage backwards if that is
possible.

Thanks Peter.  I will check that.

As it is right now, the governor will not move at all. It's acts like it's stuck wide open for some reason. Using the little lever above the governor linkage, I can slide the fuel rail back and forth.

This is all still at the factory setting.

Zack & Ginny Methvin
1998 U270 36' WTFE
Build# 5242 (E-25 code)
FMCA# 548390
Longview, Texas

Re: Generator Won't Start

Reply #36 –
On mine the throttle or governor linkage will move just a little and the l wonder if the linkage
behind the governor linkage can be used as a shut down. Next time I start my generator I will
check.
Peter and Frieda Morin
1999 36ft. U320 Foretravel
Build # 5436
1998 Suzuki Sidekick Sport

Re: Generator Won't Start

Reply #37 –
Quote from: oldguy –
On mine the throttle or governor linkage will move just a little and the l wonder if the linkage
behind the governor linkage can be used as a shut down. Next time I start my generator I will
check.

Thanks Peter.
Mine actually moves about 1/16" of an inch but that is all.
Zack & Ginny Methvin
1998 U270 36' WTFE
Build# 5242 (E-25 code)
FMCA# 548390
Longview, Texas

Re: Generator Won't Start

Reply #38 –
That seems to be the same as mine.
Peter and Frieda Morin
1999 36ft. U320 Foretravel
Build # 5436
1998 Suzuki Sidekick Sport

Re: Generator Won't Start

Reply #40 –
Tim,

That is one of the service manuals that I have been hunting for Zack and my self to get this generator back in good shape. Thanks for running this down and posting for all.

Mike
Pamela & Mike 97 U 320

"It's not what happens to you, but how you react to it that matters."

Re: Generator Won't Start

Reply #41 –
Yes Tim, this is perfect, thank you very much for posting this.
Zack & Ginny Methvin
1998 U270 36' WTFE
Build# 5242 (E-25 code)
FMCA# 548390
Longview, Texas

Re: Generator Won't Start

Reply #43 –
Hey all.
I've been talking to Mike about my gen. issue and he said something that sparked a thought / theory for me. When starting the gen. at the gen. itself. I flip the master power switch to "on", I then push the rocker switch up to the "start" position and release, the engine starts.

However, in talking to Mike today, when he pushes the rocker switch to "start" on his gen., his snaps back out of the "start" position after the engine starts. Mine doesn't, mine stays in the start mode all the time. Could the fact that mine staying in "start" mode be telling the fuel shutoff solenoid to stay open and keep dumping fuel because it is not aware the engine is running and thereby causing the overspeed and tons of black smoke signifying too much fuel being dumped? Is this possible or am I crazy, LOL?

Zack & Ginny Methvin
1998 U270 36' WTFE
Build# 5242 (E-25 code)
FMCA# 548390
Longview, Texas

Re: Generator Won't Start

Reply #44 –
Quote from: Zack & Ginny –

However, in talking to Mike today, when he pushes the rocker switch to "start" on his gen., his snaps back out of the "start" position after the engine starts. Mine doesn't, mine stays in the start mode all the time. Could the fact that mine staying in "start" mode be telling the fuel shutoff solenoid to stay open and keep dumping fuel because it is not aware the engine is running and thereby causing the overspeed and tons of black smoke signifying too much fuel being dumped? Is this possible or am I crazy, LOL?

You might be onto something.  We don't have an Isuzu-based generator manual on the forum (engine, yes, and now shop manual, but not entire generator).  Engine manual shows a multi-position key (automotive) with an auto-retract from start to run.  If that rocker switch is supposed to be momentary and isn't returning, it might send an erroneous/continuous open choke-type signal to the start/fuel controls.
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Generator Won't Start

Reply #45 –
Mine is a 10k with an Isuzu 3ld1 the start switch on  mine snaps back when you let go of it.
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country

Re: Generator Won't Start

Reply #46 –
I think Mike might of found the issue!
Richard & Betty Bark & Keiko our Golden Doodle
2003 U320T 3820 PBDS
Build # 6215
MC # 16926
2016 Chevrolet Colorado 4X4 diesel

Re: Generator Won't Start

Reply #47 –
Quote from: rbark –
I think Mike might of found the issue!

Yes, I think this very well may be the issue. As soon as Mike said his snaps back to center, I thought, wait a minute, mine stays on start.

**** UPDATE ***** Just talked to Jeff @ Powertech, he said my start switch staying in the start position will not cause the engine to overrev to max throttle. He thinks there is something going on with the fuel rack. So, back to the drawing board until I get a chance to pull the injector pumps again. 
Zack & Ginny Methvin
1998 U270 36' WTFE
Build# 5242 (E-25 code)
FMCA# 548390
Longview, Texas

Re: Generator Won't Start

Reply #48 –
1) The fuel solenoid controls fuel going to the injectors, not from, no dumping.


2) If you remove the injector rack cover you can observe the injector rack in action as you start, or try to start the engine.
Tim Dianics
Pam Sapienza
Vader PupZilla Labrador Canine Beast (AKA Pup)
Columbia, MO
1996 U320 4000
2021 Jeep Gladiator, Diesel